考虑刀具磨损影响的CFRP复合材料钻削轴向力预测

陈逸佳; 陈燕; 晏超仁; 范文涛; 谢松峰

doi:10.13801/j.cnki.fhclxb.20201111.003

考虑刀具磨损影响的CFRP复合材料钻削轴向力预测

doi: 10.13801/j.cnki.fhclxb.20201111.003

南京航空航天大学　机电学院，南京 210016

基金项目: 国家自然科学基金(51875284)

详细信息

通讯作者:
陈燕，博士，教授，博士生导师，研究方向为难加工材料的高效精密加工技术　E-mail：ninaych@nuaa.edu.cn

中图分类号: TB332
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出版历程
- 收稿日期: 2020-08-13
- 录用日期: 2020-10-29
- 网络出版日期: 2020-11-11
- 刊出日期: 2021-07-15

Prediction of thrust force in CFRP composite drilling considering tool wear effect

College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China

摘要

摘要: 在碳纤维增强树脂(CFRP)复合材料钻削过程中，随着刀具磨损量的累积，轴向力会逐渐增加，轴向力过大会导致CFRP复合材料一系列的加工缺陷。为实现在CFRP复合材料钻削过程中随刀具磨损量的累积轴向力变化的有限元分析及预测，建立了CFRP复合材料钻削仿真模型，通过对ABAQUS仿真软件二次开发，利用Python语言开发子程序，将考虑磨损量累积的轴向力预测模型导入仿真软件，运用ABAQUS软件对CFRP复合材料钻削中轴向力进行研究，实现了随着刀具磨损量累积轴向力变化的预测功能。随后通过CFRP复合材料钻削试验，分析了轴向力随钻削孔数的变化规律，以验证轴向力的预测结果。结果表明：3D钻削有限元模型能够良好地预测实际加工过程中刀具未磨损时轴向力的大小，其误差为9.10%；在考虑磨损量累积后，轴向力预测模型能够较准确地预测实际加工过程轴向力的大小，其最大误差不超过10%。
- CFRP复合材料 /
- 钻削 /
- 有限元模型 /
- 刀具磨损 /
- 轴向力预测模型 /
- ABAQUS二次开发
Abstract: In the drilling process of carbon fiber reinforced polymer (CFRP) composite, the thrust force gradually increases with the accumulation of tool wear. Excessive thrust force can cause a series of machining defects in CFRP composite. In order to realize the finite element analysis and prediction of the thrust force changing with the accumulation of tool wear in the process of CFRP composite drilling, the simulation model of CFRP composite drilling was established. Through the secondary development of the ABAQUS simulation software, the thrust force prediction model considering the wear accumulation was imported into the simulation software by using the Python language development subroutine. The thrust force in the CFRP composite drilling was studied by using the ABAQUS software, and the prediction function of thrust force change with tool wear was realized. Then, through CFRP composite drilling experiments, the changes in thrust force with the number of drilling holes were analyzed to verify the prediction results of the model. The results show that the 3D finite element model of drilling without considering the change of wear can well predict the thrust force in the actual machining process, with the error of 9.10%. After considering the wear accumulation, the thrust force prediction model can predict the thrust force in the actual machining process, with the maximum error less than 10%.
- CFRP composite /
- drilling /
- finite element model /
- tool wear /
- thrust force prediction model /
- ABAQUS secondary development

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图 1 碳纤维增强树脂(CFRP)复合材料各强度方向示意图

Figure 1. Schematic diagram of each strength direction of carbon fiber reinforced polymer (CFRP) composite

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图 2 刀具网格模型

Figure 2. Tool mesh model

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图 3 CFRP复合材料铺层顺序及网格模型

Figure 3. Stacking sequence and mesh model of CFRP composite

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图 4 CFRP复合材料3D钻削网格模型及边界条件

Figure 4. 3D drilling mesh model and boundary conditions of CFRP composite

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图 5 CFRP复合材料钻削轴向力预测模型计算流程

Figure 5. Calculation flow chart of thrust force prediction model of CFRP composite drilling

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图 6 钻头外缘转点处切削刃钝圆(CER)测量流程

Figure 6. Measuring process of cutting edge rounding (CER) at outer edge turning point of drill bit

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图 7 CFRP复合材料钻削轴向力预测插件开发流程

Figure 7. Development process of thrust force prediction plug-in for CFRP composite drilling

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图 8 CFRP复合材料钻削轴向力预测开发插件窗口

Figure 8. Development plug-in window of thrust force prediction for CFRP composite drilling

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图 9 试验加工平台

Figure 9. Experimental processing platform

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图 10 仿真和试验CFRP复合材料钻削轴向力结果对比

Figure 10. Comparison of simulation and experimental CFRP composite drilling thrust force results

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图 11 变加工参数CFRP复合材料钻削试验轴向力预测拟合和试验结果

Figure 11. Prediction fitting and experimental results of tool life for CFRP composite drilling experiments with variable machining parameters

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图 12 CFRP复合材料钻削试验CER试验结果和拟合结果

Figure 12. Fitting and experimental results of CER for CFRP composite drilling experiments

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图 13 不同加工参数下预测和试验CFRP复合材料钻削轴向力对比

Figure 13. Comparison of predicted and experimental CFRP composite drilling thrust force under different processing parameters

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图 14 不同加工参数下仿真和预测CFRP复合材料钻削轴向力误差对比

Figure 14. Comparison of simulated and predicted CFRP composite drilling thrust force error under different processing parameters

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表 1 T800碳纤维强度性能^[17]

Table 1. Strength properties of T800 carbon fiber^[17]

CFRP strength parameter	Value
X_1t/MPa	2720
X_2t=X_3t/MPa	111
X_1c/MPa	1690
X_2c=X_3c/MPa	214
S₁₂=S₂₃=S₁₃/MPa	115
Notes: X_1t—Tensile strength in 1 direction; X_2t—Tensile strength in 2 directions; X_3t—Tensile strength in 3 directions; X_1c—Compressive strength in the 1 direction; X_2c—Compressive strength in 2 directions; X_3c—Compressive strength in 3 directions; S₁₂—Shear strength in 1-2 plane; S₂₃—Shear strength in 2-3 planes; S₁₃—Shear strength in 1-3 planes.

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表 2 YTDI-220T-FSL型冠齿钻主要参数

Table 2. Main parameters of YTDI-220T-FSL crown drill

Main parameter of tool	Value
Diameter/mm	22
Helix angle/(°)	15
Point angle/(°)	130

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表 3 钻削试验参数

Table 3. Experiment parameters of drilling

Test condition	Spindle speed/ (r·min⁻¹)	Feed rate/ (mm·r⁻¹)	Cutting speed/ (m·min⁻¹)
A	600	0.01	41.47
B	1000	0.01	69.12
C	1400	0.01	96.76
D	1800	0.01	124.41
E	600	0.02	41.47
F	1000	0.02	69.12
G	1400	0.02	96.76
H	1800	0.02	124.41
I	600	0.03	41.47
J	1000	0.03	69.12
K	1400	0.03	96.76
L	1800	0.03	124.41
M	600	0.04	41.47
N	1000	0.04	69.12
O	1400	0.04	96.76
P	1800	0.04	124.41
Drilling sequence: A B C D E F G H I J K L M N O P A B C D E F G H I J K L M N O P

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表 4 轴向力验证试验参数

Table 4. Experimental parameters of thrust force verification

Spindle speed/ (r·min⁻¹)	Feed rate/ (mm·r⁻¹)	Cutting speed/ (m·min⁻¹)
1000	0.01	69.12
1000	0.02	69.12
1200	0.01	82.94

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